Optimization of Tool Wear using Coupled RSM-GA Approach in Turning of Stainless Steel AISI 304 with Magnetic Damping of Tool Shank

Tool wear, especially flank wear, is a major concern in the manufacturing industry. Increased tool wear is caused by chatter and leads to increased surface roughness, reduced productivity and higher operating costs. It is more pronounced in the machining of difficult to cut materials such as stainle...

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Main Authors:	Amin, A. K. M. Nurul, Subir, Siti Aminatuzzuhriyah B. Haji, Arif, Muammer Din
Format:	Article
Language:	English English
Published:	Trans Tech Publications Ltd., Switzerland 2015
Subjects:	TJ Mechanical engineering and machinery
Online Access:	http://irep.iium.edu.my/46246/ http://irep.iium.edu.my/46246/ http://irep.iium.edu.my/46246/ http://irep.iium.edu.my/46246/1/Fist_page_Opt_of_tool_wear_using_RSM-GA_in_s_steel_turning_wt_mag_damp http://irep.iium.edu.my/46246/2/AMR.1115.117_Opt_of_Tool_Wear_using_RSM-GA_in_Turning_of_S_Steel.pdf

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spelling	iium-462462016-05-09T05:58:44Z http://irep.iium.edu.my/46246/ Optimization of Tool Wear using Coupled RSM-GA Approach in Turning of Stainless Steel AISI 304 with Magnetic Damping of Tool Shank Amin, A. K. M. Nurul Subir, Siti Aminatuzzuhriyah B. Haji Arif, Muammer Din TJ Mechanical engineering and machinery Tool wear, especially flank wear, is a major concern in the manufacturing industry. Increased tool wear is caused by chatter and leads to increased surface roughness, reduced productivity and higher operating costs. It is more pronounced in the machining of difficult to cut materials such as stainless steel, tool steel, Inconel and hardened Ti alloys. Additionally, unpredictable tool wear can lead to frequent shutdowns of the machining process making it difficult for full automation. Therefore, to increase productivity and to reduce costs associated with increased and unpredictable tool wear, numerous research studies have been carried out. In this research, two permanent ferrite bar magnets of 1500 Gauss strength were used to dampen the vibration of the tool shank in the turning of stainless steel AISI 304 using titanium nitride (TiN) coated carbide inserts. Mild steel fixtures were used to place the magnets beside and below the tool shank in the carraige of a Harrison M390 engine lathe. The tool overhang was kept constant at 120 mm. A small central composite design (CCD) approach in response surface methodology (RSM) was used to model the tool wear as a response of the three primary cutting parameters: cutting speed, feed, and depth of cut. Design Expert software (version 6) was used to generate the 14 experimental runs needed to develop and verify the empirical mathematical model of tool flank wear. The resultant tool flank wear was measured using both optical and scanning electron microscopes (SEM). Finally, an empirical quadratic mathematical model of tool wear was found. This model was then used as the objective function in the optimization of tool wear using genetic algorithms (GA). The optimization results predicted that the minimum tool wear was 0.0427 mm. This prediction was subsequently validated experimentally. Trans Tech Publications Ltd., Switzerland 2015-07 Article PeerReviewed application/pdf en http://irep.iium.edu.my/46246/1/Fist_page_Opt_of_tool_wear_using_RSM-GA_in_s_steel_turning_wt_mag_damp application/pdf en http://irep.iium.edu.my/46246/2/AMR.1115.117_Opt_of_Tool_Wear_using_RSM-GA_in_Turning_of_S_Steel.pdf Amin, A. K. M. Nurul and Subir, Siti Aminatuzzuhriyah B. Haji and Arif, Muammer Din (2015) Optimization of Tool Wear using Coupled RSM-GA Approach in Turning of Stainless Steel AISI 304 with Magnetic Damping of Tool Shank. Advanced Materials Research, 1115. pp. 117-121. ISSN 1662-8985 http://www.scientific.net/AMR.1115.117 10.4028/www.scientific.net/AMR.1115.117
repository_type	Digital Repository
institution_category	Local University
institution	International Islamic University Malaysia
building	IIUM Repository
collection	Online Access
language	English English
topic	TJ Mechanical engineering and machinery
spellingShingle	TJ Mechanical engineering and machinery Amin, A. K. M. Nurul Subir, Siti Aminatuzzuhriyah B. Haji Arif, Muammer Din Optimization of Tool Wear using Coupled RSM-GA Approach in Turning of Stainless Steel AISI 304 with Magnetic Damping of Tool Shank
description	Tool wear, especially flank wear, is a major concern in the manufacturing industry. Increased tool wear is caused by chatter and leads to increased surface roughness, reduced productivity and higher operating costs. It is more pronounced in the machining of difficult to cut materials such as stainless steel, tool steel, Inconel and hardened Ti alloys. Additionally, unpredictable tool wear can lead to frequent shutdowns of the machining process making it difficult for full automation. Therefore, to increase productivity and to reduce costs associated with increased and unpredictable tool wear, numerous research studies have been carried out. In this research, two permanent ferrite bar magnets of 1500 Gauss strength were used to dampen the vibration of the tool shank in the turning of stainless steel AISI 304 using titanium nitride (TiN) coated carbide inserts. Mild steel fixtures were used to place the magnets beside and below the tool shank in the carraige of a Harrison M390 engine lathe. The tool overhang was kept constant at 120 mm. A small central composite design (CCD) approach in response surface methodology (RSM) was used to model the tool wear as a response of the three primary cutting parameters: cutting speed, feed, and depth of cut. Design Expert software (version 6) was used to generate the 14 experimental runs needed to develop and verify the empirical mathematical model of tool flank wear. The resultant tool flank wear was measured using both optical and scanning electron microscopes (SEM). Finally, an empirical quadratic mathematical model of tool wear was found. This model was then used as the objective function in the optimization of tool wear using genetic algorithms (GA). The optimization results predicted that the minimum tool wear was 0.0427 mm. This prediction was subsequently validated experimentally.
format	Article
author	Amin, A. K. M. Nurul Subir, Siti Aminatuzzuhriyah B. Haji Arif, Muammer Din
author_facet	Amin, A. K. M. Nurul Subir, Siti Aminatuzzuhriyah B. Haji Arif, Muammer Din
author_sort	Amin, A. K. M. Nurul
title	Optimization of Tool Wear using Coupled RSM-GA Approach in Turning of Stainless Steel AISI 304 with Magnetic Damping of Tool Shank
title_short	Optimization of Tool Wear using Coupled RSM-GA Approach in Turning of Stainless Steel AISI 304 with Magnetic Damping of Tool Shank
title_full	Optimization of Tool Wear using Coupled RSM-GA Approach in Turning of Stainless Steel AISI 304 with Magnetic Damping of Tool Shank
title_fullStr	Optimization of Tool Wear using Coupled RSM-GA Approach in Turning of Stainless Steel AISI 304 with Magnetic Damping of Tool Shank
title_full_unstemmed	Optimization of Tool Wear using Coupled RSM-GA Approach in Turning of Stainless Steel AISI 304 with Magnetic Damping of Tool Shank
title_sort	optimization of tool wear using coupled rsm-ga approach in turning of stainless steel aisi 304 with magnetic damping of tool shank
publisher	Trans Tech Publications Ltd., Switzerland
publishDate	2015
url	http://irep.iium.edu.my/46246/ http://irep.iium.edu.my/46246/ http://irep.iium.edu.my/46246/ http://irep.iium.edu.my/46246/1/Fist_page_Opt_of_tool_wear_using_RSM-GA_in_s_steel_turning_wt_mag_damp http://irep.iium.edu.my/46246/2/AMR.1115.117_Opt_of_Tool_Wear_using_RSM-GA_in_Turning_of_S_Steel.pdf
first_indexed	2023-09-18T21:05:50Z
last_indexed	2023-09-18T21:05:50Z
_version_	1777410926455029760

Optimization of Tool Wear using Coupled RSM-GA Approach in Turning of Stainless Steel AISI 304 with Magnetic Damping of Tool Shank

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